Experimental Study of a Novel Ultrasonic Vibration-Assisted Structure for Radial Milling

Yu He,Ping Zou,Shuyan Wang,Luping Ren

doi:10.1155/2021/5590560

Abstract

A novel ultrasonic vibration-assisted structure for radial milling is proposed, and the ultrasonic vibration-assisted radial milling (UVARM) is further studied in terms of theoretical model and milling experiment. The motion and feed characteristics of UVARM are also analyzed. A special fixture is designed to construct the experimental platform of UVARM, in which the vibration is applied to the workpiece along the radial direction. The preliminary results show that with the increase of spindle speed, the milling force in both conventional cutting (CC) and UVARM experiments tends to increase. In addition, when the feed per tooth increased, the milling force increased. With the involvement of ultrasonic vibration, the milling force is significantly reduced, with the maximum reduction reaching 20%. The comprehensive analysis showed that there was a decrease of about 10% to 25% in the ultrasonic case compared with the conventional method. It is also found that UVARM can inhibit the production of a built-up edge. With the ultrasonic vibration, the burrs on the processed surface are also reduced, and the grooves left by tool traces are shallower. Compared with conventional milling, the roughness value of the machined surface obtained by UVARM is reduced by 10% to 32%. The experimental results also show that UVARM can effectively improve the dimensional accuracy of the workpiece.

Highlights

An ultrasonic vibration-assisted cutting (UVAC) is a kind of compound machining method which combines ultrasonic vibration with conventional machining
E vibration-assisted milling trajectory of one of the single tool tip is simulated using MatLab as shown in Figure 3. is work mainly focuses on the feed direction vibration, including the effect of ultrasonic vibration amplitude, feed per tooth and spindle speed on the milling force, workpiece processing precision, and dimensional precision. e milling cutter can be regarded as several small turning tools
The UVA milling experiment setup is constructed. e material 6061-T6 is taken as the object to study the effect of cutting parameters on the experiment output, e.g., cutting force, workpiece surface roughness, and dimensional accuracy. e preliminary results can be summarized as follows

Summary

Introduction

An ultrasonic vibration-assisted cutting (UVAC) is a kind of compound machining method which combines ultrasonic vibration with conventional machining. Compared with conventional machining (CM), UVAC can effectively improve the dimension precision, surface quality, and stability of the processing system. E experimental results show that applying ultrasonic vibration is helpful to improve the cutting force, tool life, and machining accuracy for hard brittle materials machining [1]. Gong et al reported that when UVAC was used to process hard and brittle materials, better machining quality could be achieved by adopting larger cutting depth and smaller feed rate [7]. Few works have been focused on the study of that when the vibration is applied to the workpiece along radial direction during ultrasonic vibration-assisted machining. E influence of each feed per tooth, spindle speed, vibration amplitude, and other process parameters on UVARM force, dimension precision, and surface quality was studied through a single-factor experiment. It is verified that the UVARM can effectively solve the disadvantages of ultraprecision machining such as difficulty in chip removal, severe tool wear, and high processing cost

Kinematic Analysis of Tool Trajectory of UVARM

UVARM Experiment

Findings

Conclusion